Hurricane proof modular building structure

ABSTRACT

Disclosed is a modular hurricane proof modular building structure. The structure includes a dual wall system that includes a rugged exterior constructed primarily of concrete and steel and a finished interior, with a thermal break in-between to prevent heat from the concrete and metallic structure from heating the interior surfaces. The thermal break also prevents moisture and water vapor transfer, and therefore, significantly reduces mold growth. The building combines the best of industry desired characteristics in a single modular constructed building, combining hurricane force wind resistance, relocateability, modularity, fire and heat resistance, mold resistance and substantial concrete construction.

CROSS REFERENCE TO RELATED APPLICATION

This application is a nonprovisional of U.S. Patent Application Ser. No. 60/506,498, filed Sep. 26, 2003, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

This invention relates generally to modular building systems, and more particularly to hurricane proof modular building structures.

Increasingly, states that are confronted with the possibility of tropical storms and hurricanes have promulgated safety standards in the construction of certain buildings aimed at minimizing damage to those buildings in hurricane-type situations, in effect requiring the buildings to be “hurricane proof” to the extent possible, to for example, withstand extremely high level winds and high velocity projectiles that are associated with such wind levels. In response, the industry has moved towards concrete construction. In the modular building industry, it is a continuing design goal to meet or exceed the state imposed construction parameters for hurricane-resistance, and at the same time maintain a level of portability for the modularly constructed buildings.

Modularly constructed building structures are advantageous in that they provide shelter from the elements in which a variety of activities can be housed, and are relatively easily transported from one locale to another. Moreover, such structures can typically be assembled in stackable sections, or sections placed side-by-side (i.e., the sections are positioned adjacent each other), right on site after being transported. Modular building structures can be used for production of single and multi-unit or multi-family homes, as well as apartments, condominiums, classrooms, general offices, medical facilities, commercial buildings and the like.

Further, in the modular building structure industry, there are increasing requirements and market forces aimed at improving the structure resistance to mold and combustion. It has been found that there is a need for a modular building with substantial concrete construction, therefore meeting the hurricane-proof requirements, as well as providing a fire-resistant (or non-combustible) structure with mold-resistant characteristics.

One construction technique to address the above includes building a wall within a wall. However, such a procedure promotes heat transfer and moisture/vapor transfer that leads to mold growth. A need exists to improve the wall within a wall construction to create thermal barriers and moisture/vapor barriers.

Many modular building structures are custom designed. However, building structures can also be designed according to standard or pre-fabricated building templates as well. Today's modular building structures are computer-engineered to meet national building codes. They can be precisely engineered for increased structural durability. High quality can be maintained by inspection during construction process. In one construction example, a modular building structure is delivered to a desired site, after which individual modular structures or “modules” are assembled into an overall modular building structure.

In general, the metrics of building construction costs break out on a per square foot basis. It is a continuous goal to reduce the construction costs of the modular structures. To this end, it would be desirable to provide a modular building structure that, while meeting all applicable building codes and other standards, is simpler to construct than known modular building structures. For example, a building structure comprising fewer pieces, parts or other components in its construction is desirable. Similarly, material selection for such modular building structures is key, in that the material type and placement can result in a building structure of having a greater useful life and durability.

It would also be desirable to use stronger and more durable modules or substructures in making the overall modular building structure. This can lead to a decrease in the number of supports or braces in a given area, thereby reducing modular building structure costs on a square foot basis.

Accordingly, it would be desirable to provide a modular building structure that combines the best of industry desired characteristics in a single modular constructed building, combining hurricane force wind resistance, relocateability, modularity, fire and heat resistance, mold resistance and substantial concrete construction.

SUMMARY OF THE INVENTION

This invention relates generally to a hurricane proof modular building structure, and more specifically to a hurricane proof modular building structure that has a combination of hurricane force wind resistance, relocateability, modularity, fire and heat resistance, mold resistance and substantial concrete construction.

In one aspect of the invention, a hurricane proof modular building structure is disclosed. The building structure includes a floor structure for use in a hurricane proof modular building structure. The floor structure includes: a first floor structure portion and a second floor structure portion each comprising: a plurality of metal support structures; a non-composite deck disposed on top of the support structures; and a metal cross-member connected to the metal support structures. The first and second metal cross members are in opposing, spaced apart relationship with respect to each other to define a floor seam that permits separation of the floor structure along the floor seam;

The building also includes a wall structure comprising: an outer concrete layer; a plurality of metal studs spaced apart from each other and positioned adjacent to, but separated from, the concrete layer, to create metal stud-concrete layer thermal gaps; a first insulation layer located between the plurality of metal studs and adjacent the concrete layer; a second insulation layer positioned adjacent the first insulation layer; and a mold resistant layer located adjacent the second insulation layer. The plurality of thermal gaps and at least one of the first and the second insulation layers create a thermal break. The structure also includes a roof structure, the roof structure comprising: a roof portion having load-bearing perimeter; and an inclined roof comprising opposing slanted portions reaching a central apex such that the apex of the slanted portions does not extend above the load-bearing perimeter.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are disclosed with reference to the accompanying drawings and are for illustrative purposes only. The invention is not limited in its application to the details of construction or the arrangement of the components illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in other various ways. Like reference numerals are used to indicate like components.

FIG. 1 is a perspective view of one embodiment of a hurricane proof modular building structure according to one aspect of the present invention;

FIG. 2 is top view illustrating a floor plan of the hurricane proof modular building structure of FIG. 1;

FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 1;

FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 1;

FIG. 5 is an enlarged detailed view of a portion of the hurricane proof modular building structure shown in FIG. 4;

FIG. 6 is an enlarged detailed view of a portion of the hurricane proof modular building structure taken along line 6-6 of FIG. 2; and

FIG. 7 is a perspective view of a plurality of hurricane proof modular building structures showing their modularity and stackability.

DETAILED DESCRIPTION

FIG. 1 is a perspective view of one embodiment of a hurricane proof modular building structure 10 according to one aspect of the present invention. By “hurricane proof” it is meant that the structure is built to withstand and be resistant to high winds (e.g., tropical storm level winds up to about 75 mph, hurricane force winds from about 75 mph up to about 150 mph, and the like). The structure is “modular” in that the structure is designed an built with standardized units or dimensions so as to promote ease of assembly and repair. As will be described in greater detail below, each such structure is built from prefabricated and standardized parts and/or component pieces. Various applications are intended and contemplated for the structure shown, and these include: single and multi-unit or multi-family homes, as well as apartments, condominiums, support facilities, general offices, medical facilities, light manufacturing, commercial buildings and the like, although, in a preferred embodiment, the structure can be used for a classroom. In a typical construction, the modular building structure can include such features as door 12 and windows 14, replicating features found in permanent building structures.

As shown, the structure 10 is generally rectangular, although other shapes are contemplated and considered within the scope of the present invention. Structure 10 includes a roof structure 16 that typically inclined downwardly from a roof centerline or apex 18 to promote drainage of water off of or away from the roof via, as shown, drainage pipes 20 to a grounded location. The structure shown represents a combination of two half modular sections placed together and connected (as will be shown and described in following) in side-by-side fashion along line 22 after being delivered to the site of use. The structure shown and described herein represents a culmination of a transition or trend in the modular building marketplace towards what is referred to as “concrete construction”. Accordingly, in one embodiment, the structure includes walls 24 that is a poured concrete wall. The walls, notwithstanding the windows, renders the structure substantially bullet-proof.

The structure 10 is constructed for several design parameters, for example, the floor structure 36 of FIG. 5 is designed for a 50 PSF live load; roof structure 16 is designed for a 30 PSF live load snow-to-ground load; and the overall structure 10 is designed to withstand an overall wind speed of 150 mph, and a class C wind exposure.

Advantageously, structure 10 (i.e., both its exterior and in its interior) can be delivered to a site as a substantially complete module (i.e., about 95% finished). This results in a cost reduction for the user, and decreases time to use (e.g., on the order of about a day or two) from the time of delivery of module structure 10 to the site of use.

FIG. 2 is top view illustrating a floor plan of the hurricane proof modular building structure of FIG. 1. Doors 12 are shown in an open position. Centerline 22 delineates the location at which the two half modular sections 26 a-b are combined to create the overall building structure 10. One advantage of this structure design is that each of the sections 26 a-b are easily transported to a specified location. For example, each of the half structures can be brought separately (e.g., via truck) to a job site. In addition, each of the structures 26 a-b can be used in locations that would otherwise be inaccessible due to the need to previously transport structure as a whole. Walls 24 define structure interior portions 28 a-b. Because of the high level of structural support provided by walls 24, portions 28 a-b are “open-concept” in that other structure support members (e.g., beams, pillars, etc.) are not required. Therefore, a variety of uses can be accomplished within the interior, and the interior is highly adaptable to such uses.

FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 1, showing the building structure 10, and in particular, illustrating a recessed roof structure 16, the roof structure supported by walls 24, connected to a floor structure 40. Roof structure 16 comprises a raised roof portion 30 defining load-bearing perimeter, and further including an inclined roof 32 comprising two opposing slanted roof portions 34 a-b. The roof portions are opposingly sloped or pitched so as to reach or define a central apex 35, which coincides with a roof centerline 18. The apex of the slanted portions 34 a-b does not extend above the load-bearing perimeter of the roof portion 30, thereby permitting or facilitating stacking of at least one additional modular building structure of similar size and shape thereon. Stated another way, the inclined roof first and second opposingly inclined roof structure portions are in spaced apart relationship with respect to each other to define a roof seam that permits separation of the inclined roof along the seam. Since the raised roof portion is preferably substantially level, and since the roof is recessed from the raised roof portion, dual benefits are achieved. Namely, stacking of a plurality of modular structures is facilitated, while simultaneously permitting drainage along the two opposing slanted portions away from the structure itself.

FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 1 showing interior portions 28 a-b of half modular sections 26 a-b. Although structures 26 a-b are separate and distinct, they are joined to form a single unit in a cohesive fashion, for example, by common interior finishing of walls 33 and drop ceiling 37. In this way, interior portions 28 a-b can be used to create a single interior space.

FIG. 5 is an enlarged detailed view of a portion of the hurricane proof modular building structure shown in FIG. 4. Specifically, a floor structure 36 for use in the hurricane proof modular building structure 10 is shown. The floor structure comprises a first floor structure portion 38 having a plurality of metal support structures 40 (e.g., steel I-beams), one of which is shown, and a non-composite deck 42 disposed on top of the support structures 40. The first floor structure portion 38 includes a metal cross-member 44 connected to the metal support structures. The floor structure 36 also includes a second floor structure portion 46 having a second plurality of metal support structures 48 (again, one of which is shown) and a second non-composite deck 50 disposed on top of the support structures 48. The second floor structure portion 46 also includes a second metal cross-member 52 connected to the metal support structures 48. The first and second metal cross members are in opposing, spaced apart relationship with respect to each other so as to define a floor seam 54 that permits separation of the floor structure along the floor seam or channel. The seam or channel 54 can be bridged using, for example, a lightweight concrete deck. The non-composite deck can comprise, by way example, a 24 gauge galvanized steel. The floor structure can be finished by including a concrete deck 43 over the non-composite deck.

Advantageously, the inventive floor structure results in a hurricane proof modular building structure that does not comprise a knockout floor section. “Knockout” sections are typically used during the installation of indoor plumbing. “Knockout sections” are sections that are removable prior to such installation (e.g., at the site), and then following installation, the sections are re-poured, for example, with a concrete material.

FIG. 6 is an enlarged detailed view of a portion of the hurricane proof modular building structure taken along line 6-6 of FIG. 2. Referring now to FIGS. 5 and 6, a wall structure 56 for use in the inventive hurricane proof modular building structure 10 (FIG. 5) is shown in detail. The wall structure comprises an outer concrete layer 58 and a plurality of metal studs 60 spaced apart from each other and positioned adjacent to, but separated from, the concrete layer to create metal stud-concrete layer thermal gaps 62. The wall structure 56 further includes a first insulation layer 64 located between the plurality of metal studs 60 and adjacent the concrete layer 58. A second insulation layer 66 is positioned adjacent the first insulation layer 64 and a mold resistant layer 68 is located adjacent the second insulation layer 66. The plurality of thermal gaps 62 and at least one of the first and the second insulation layers 64, 66 are utilized to create a thermal break 70, and a plurality of thermal breaks are included in the structure. Typically, the concrete layer 58 is of prescribed thickness and density so as to create a moisture-impermeable external vapor barrier. And the vapor barrier and thermal break create substantially mold-resistant conditions within the wall structure. Advantageously, hurricane proof modular building structure comprising a vapor proof wall section. The building structure can include a poured concrete exterior modular wall section having a finished interior wall. It can be said that the hurricane proof modular building structure comprises a wall within a wall, providing both a thermal break and a moisture barrier. In one embodiment, a foam seal insulation system can be used to provide the thermal break, eliminating the need to use mechanical fasteners.

Advantageously, the wall structure is provided with both a plumbing entry and a plumbing discharge to permit indoor plumbing while also providing for ease of hook up and disconnect to enhance and facilitate mobility of the structures. In such embodiments, it can be said that the plumbing entry and the plumbing discharge do not run through the building structure floor. Because the plumbing entry and discharge can be positioned to run above the floor, and through the exterior wall (as opposed to through the floor), there is no need to utilize a “knock-out” portion of the floor during plumbing installation at the site.

The present invention provides a wall structure that includes a space defined by the steel studs and the concrete walls, as well as insulation between the steel studs and the interior drywall, in order to create a thermal break. The concrete provides a built-in, external vapor barrier. The combination of the vapor barrier and the thermal break serves to eliminate conditions that allow mold to form, such as mold that results from moisture and temperature change-induced condensation.

Referring to FIG. 5, roof structure 16 is supported by structural steel make beam 72 embedded on a light track 74 and cross beam steel joist 75, joined by steel angles 76, which support roofing materials, such as corrugated deck pan 78. A roofing material 80 (e.g., EPDM) may be applied over the deck pan 78. Between roofing material 80 and deck pan 78 is a layer (e.g., 2 inches in thickness) of insulation material (e.g., polyiso) to provide additional insulation and heat retention within structure 10. The advantage of using a steel I-beam, as opposed to, for example, a cast concrete I-beam, provides for a reduced-weight construction, which enhances portability of the structures.

FIG. 7 is a perspective view of a plurality of hurricane proof modular building structures 10 a-c showing both their modularity and stackability. The modular building structures shown include a combination of industry-desired characteristics including hurricane force wind resistance, relocateability, modularity, fire and heat resistance, mold resistance and substantial concrete construction. The hurricane proof modular building structure is suitable for human use or habitation. As shown, the structures are formed into a modular building structure arrangement that is two stories high and two structures wide. However, it is contemplated that other arrangements could be of different height or width, as applications vary and conditions so dictate. As referenced previously, the concealed interior slope for drainage, coupled with external load-bearing vertical wall members results in a design that provides for such stackability to create multi-story modular buildings.

Preferably, in order to eliminate the need for battens to conceal joints and mechanical fasteners, beveled edge drywall panels are used and fasteners are covered with spackle. A specially-designed paint and application system can be used to spray, for example, for colors at once over the walls to provide a suitable finish.

The present invention combines multiple beneficial features in one composite structure. While the present invention has been described in terms of the preferred embodiment, it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims. 

1. A floor structure for use in a hurricane proof modular building structure, the floor structure comprising: a first floor structure portion comprising: a plurality of metal support structures; a non-composite deck disposed on top of the support structures; and a metal cross-member connected to the metal support structures; and a second floor structure portion comprising: a second plurality of metal support structures; a second non-composite deck disposed on top of the support structures; and a second metal cross-member connected to the metal support structures; wherein the first and second metal cross members are in opposing, spaced apart relationship with respect to each other to define a floor seam that permits separation of the floor structure along the floor seam.
 2. The floor structure of claim 1 wherein the first and second floor structure portions do not include either a plumbing entry or a plumbing discharge.
 3. The floor structure of claim 1 wherein the first and second floor structure portions do not include any knockout sections.
 4. The floor structure of claim 1 wherein the floor structure is designed for a 50 PSF live load.
 5. The floor structure of claim 1 further comprising a concrete deck layer formed over the non-composite deck.
 6. A wall structure for use in a hurricane proof modular building structure, the wall structure comprising: an outer concrete layer; a plurality of metal studs spaced apart from each other and positioned adjacent to, but separated from, the concrete layer, to create metal stud-concrete layer thermal gaps; a first insulation layer located between the plurality of metal studs and adjacent the concrete layer; a second insulation layer positioned adjacent the first insulation layer; and a mold resistant layer located adjacent the second insulation layer; wherein the plurality of thermal gaps and at least one of the first and the second insulation layers create a thermal break.
 7. The wall structure of claim 6 wherein the concrete layer is of prescribed thickness and density so as to create a moisture-impermeable external vapor barrier.
 8. The wall structure of claim 7 wherein the vapor barrier and thermal break create substantially mold-resistant conditions within the wall structure.
 9. A roof structure for use in a hurricane proof modular building structure, the roof structure comprising: a roof portion having load-bearing perimeter; an inclined roof comprising opposing slanted portions reaching a central apex such that the apex of the slanted portions does not extend above the load-bearing perimeter.
 10. The roof structure of claim 9, wherein the inclined roof further comprises first and second opposingly inclined roof structure portions that are in spaced apart relationship with respect to each other to define a roof seam that permits separation of the inclined roof along the roof seam.
 11. The roof structure of claim 9 wherein the load-bearing perimeter roof portion permits stacking of a plurality of roof structures and drainage along the two opposing slated portions.
 12. The roof structure of claim 9 wherein the first and second roof portions are disposed below the perimeter so as to receive another modular structure thereon.
 13. The roof structure of claim 9 wherein the roof structure is designed for a 30 PSF live load snow-to-ground load.
 14. A hurricane proof modular building structure comprising: a floor structure for use in a hurricane proof modular building structure, the floor structure comprising: a first floor structure portion comprising: a plurality of metal support structures; a non-composite deck disposed on top of the support structures; and a metal cross-member connected to the metal support structures; and a second floor structure portion comprising: a second plurality of metal support structures; a second non-composite deck disposed on top of the support structures; and a second metal cross-member connected to the metal support structures; wherein the first and second metal cross members are in opposing, spaced apart relationship with respect to each other to define a floor seam that permits separation of the floor structure along the floor seam; a wall structure for use in a hurricane proof modular building structure, the wall structure comprising: an outer concrete layer; a plurality of metal studs spaced apart from each other and positioned adjacent to, but separated from, the concrete layer, to create metal stud-concrete layer thermal gaps; a first insulation layer located between the plurality of metal studs and adjacent the concrete layer; a second insulation layer positioned adjacent the first insulation layer; and a mold resistant layer located adjacent the second insulation layer; wherein the plurality of thermal gaps and at least one of the first and the second insulation layers create a thermal break; and a roof structure for use in a hurricane proof modular building structure, the roof structure comprising: a roof portion having load-bearing perimeter; an inclined roof comprising opposing slanted portions reaching a central apex such that the apex of the slanted portions does not extend above the load-bearing perimeter.
 15. The hurricane proof modular building structure of claim 14 a thermal break and a moisture barrier.
 16. The hurricane proof modular building structure of claim 14 further comprising a poured concrete exterior modular wall that can withstand a wind speed of at least 150 mph.
 17. The hurricane proof modular building structure of claim 14 wherein the building is suitable for human use or habitation.
 18. The hurricane proof modular building structure of claim 14 wherein the wall structure further comprises a plumbing entry and a plumbing discharge, and wherein the plumbing entry and the plumbing discharge run through at least one of the wall layers. 19 The hurricane proof modular building structure of claim 14 wherein the wall structure further comprises a plumbing entry and a plumbing discharge, and wherein the plumbing entry and the plumbing discharge does not run through a floor.
 20. The hurricane proof modular building structure of claim 14 wherein the building structure has a combination of hurricane force wind resistance, relocateability, modularity, fire and heat resistance, mold resistance and substantial concrete construction. 